Insulating material and method of manufacturing the same



F. C. EMRICK. INSULATING MATERIAL AND METHOD OF MANUFACTURING THE SAME.

Patented Aug. 15, 1922;

APPLICATION FILED FEBJIT. I921.

ATENT 'oFFlca.

FRANK C. EMRICK, OF KALAMAZOO, MICHIGAN.

INSULATING MATERIAL AN D METHOD OF MAIIUFACTURING THE SAME.

Specification of Letters Patent. Patented Aug. 15, 1922.

Application filed February 17, 1921. Serial No. 445,629.

concern:

Be it known that I, FRANK C. EMRICK, a citizen of the United States, residing at the city and county of Kalamazoo, State of Michigan, have invented certain new and useful Improvements in Insulating Materials and Methods of Manufacturing the Same, of which the following is a specifioation.

This invention relates to an improved insulating material and method of manufacturing the same.

The main objects of this invention are: First, to provide an improved insulating material from mineral wool by a felting process, the resulting product being of a resilient comparativel light character and at the same time of su stantial strength permitting its use in various relations where insulation is desirable.

Second, to provide an improved method of manufacturing insulating material from mineral wool by which the material may be effectively and rapidly manufactured.

Third, to provide an improved methodof manufacturing insulating material from mineral wool whereby sheets or blocks of varying thickness may be conveniently produced.

Fourth, to provide an improved insulating material of mineral wool which possesses substantial resiliency and is capable of use in various relatlons where insulation is required.

Further objects, and objects relating to structural details, will definitel appear from the detailed description to ollow.

I accomplish the objects of my invention by the devices and means described in the following specification. The invention is clearly defined and pointed out in the claims.

A structure which is a preferred embodiment of my'invention is clearly illustrated in the accompanying drawing, forming a part of this specification, in which:

Fig. I is a detail view, mainly conventional, of an apparatus for carrying out my improved method or process.

Fig; II is a conventional side elevation of a press illustrating one step in the manufacture of my improved insulating material.

Fig. III is a conventional illustration of a drier illustrating another step in the manufacture of my improved insulating material.

Fig. IV is an edge view of one of the insulating blocks.

Fig. V. is an edge view of one of the insulating blocks after the same has been pasted to a sheet of paper.

In the drawing similar reference characters refer to similar parts throughout the several views. I

Referring tothe drawing, the apparatus illustrated in Fi I comprises a mixing tank 1 in which is e minera l .wool is placed and agitated in water ldy jmean'sbf an air blastfthe 'tankhaving 'a perforated air pipe 2 disposed in the bottom thereof and con-- nected to the air tank or receiver 3 to which air is supplied under pressure from a suitable source, not illustrated. a

The delivery of the air to the mixing tank is controlled by the valve 4:. The mineral wool is placed in the mixing tank with water. containing laundry starch. I find in practice that one pound of laundry starch to twelve hundred pounds of water produces satisfactory results, although the proportion of water and starch may be very considerably varied and a' desirable product still produced.

The material is agitated in the tank by the air blast until the fibres are well separated, that is, knots or bunches of the fibres are thoroughly broken up. The material is then transferred by means of the. centrifugal pump 5 to the charging tank 6, the connection from the mixing tank to the pump being the pipe 7 controlled by the valve 8, while the pipe 9 connecting the pumpto the charging tank is controlled by the valve 10.

The charging tank is connected with the air receiver 3 by meains of the pipe 11 which has a valve 13 therein, the pressure connection being at the top of the charging tank. The felting box 14 is connected to the bottom of the charging tank by means of the pipe 15 and is controlled by the valve 16.

ese parts are shown mainly in, conventional form.

After a charge is pumped from the mixing pump to the charging tank the valve 10 is closed and the valve 13 opened allowing the air under pressure to enter the charging tank placing the charge under high pressure therein, preferably not less than twenty oundsper square inch. This may be varied and T have emplo ed as high as fifty-five pounds pressure. T 1e valve 16 is then opened allowing the char e to be. ejected by the air blast or force 0. the air against the felting screen 17.

A funnel 18 with discharge ipe 19 is provided for the felting box. T is enables the collection of the water so that it may be re-used in the mixin tank.

The screen 17 is detac ably secured to the felting box. The details of the attachment are not part of this invention and are not illustrated or described herein.

The felted block or sheet is subjected to a press 20, shown conventionally in Fig.

H, and from the press it is taken to the drier 21, shown conventionally in Fig. Hi.

In practice, I carry out these steps of felting and pressing by the aid of a machine s ecially desi ed for the purpose whereby t e material is discharged under the pressure to the felting screens and ressed as successive steps, the machine being of the general type of the machine shoWn'in-Letters Patent #891,331, June 23, 1908. The dried blocks or sheets 22 are preferably again placed in the press, which renders them quite flexible Without destroying or materially injuring the strength or integrit thereof.

ere it is advantageous to use the material in the form of sheets I preferably paste the felted blocks or sheets 22 upon sheets of paper 23 which adapts them for various uses where asbestos paper is now quite widely used. 1

ll am not able to state definitely the action of the starch inasmuch as the amount used is so smaall in proportion to the mineral wool that its action is not clear. I have observed, however, that the starch has no affinity for the commercial mineral wool manufactured from glass, but T have reached the conclusion that under the pres- Sure the liquid carrying the starch is forced into the minute tubular fibres and into intimate contact with the same.

I have found further that high pressure is necessaary in order to secure the result, that is, .With low pressures no material ad vantage is apparent from the use of the starch. The result of the use of starch under high pressure is very marked, the product being rendered much stronger-and its integrity greatly enhanced. At the same timethe individual character of the fibres,

which appear to be individually strengthened, and also the advantages as insulating material are retained.

A further advantage is, when subjected to a high degree of temperature my improved insulating material is not in anywise deteriorated.

There is no evidence that the starch has 1? an amount of starch is used which would constitute a binder in the sense of an adhesive coating,'as ordinarily understood, such binder will char and discolor at 500 F. or 600 F.

lit is in view of these considerations that I am unable. to state exactly the action of the starch.

' By my improved method I am enabled to manufacture the insulating material very rapidly and in relatively thin sheets or in blocks as may be desired, the process being a distinctly felting process, which, so far as I am aware,,has not been successfully carried out or practised heretofore with material of this character.

. l have illustrated an apparatus for carrying out my method mainly in conventional form as I believe the disclosure made will invention relates to carry out the same in the manner best adapted for the particular product required. The proportion of starch used in the felting process may, as stated, he very considerably varied and a desirable product will produced, the proportion stated, however, will be found very satisfactory. The quantity used should not be sufficient to destroy the individual character of the fibres.

- Having thus described my invention, what I c aim as new and desire to secure by Letters Patent, is:

l. The method of manufacturing insulating material, from mineral wool consistlng of agitatlng the mineral wool in water containing laundry starch by means of an air blast, felting the wool and such starch containlng water, subjecting to a high pressure and discharging while under such pressure upon a screen, pressing, and drying.

2. The method of manufacturing insu lating material from mineral wool consisting of agitating the mineral wool in water containing laundry starch, subjecting to high pressure, and felting.

3. The method of manufacturing insulating material from mineral fibre consisting pf agitating mineral fibre in water containing laundry starch, subjecting the mineral fibre and such starch containing water to pressure, and felting by discharging while under pressure upon a felting screen.

4'. The method of manufacturing insulatingmaterial from mineral wool consistby the aid of water containing ing 0t felting laundry starch.

'5. The method of rnanufact-t ring insulating material from mineral wool consistdestroying the individual character of the ing of felting by the aid of water containfibres. I

ing laundry starch in the proportion 'of' In witness whereof, I have hereunto set about one pound of starch to twelve hun my hand and seal in the presence of two 5 dred Rounds of lvatefr. f v Witnesses.

-6. r s an artic e o manu acture, an insu- J lating material comprising mineral wool- FRANK EMRICK' felted with the aid of water containing Witnesses: starch, the starch being incorporated with LEWIS GEO. Summit,-

10 the mineral wool throughout but without F. C. GIBBS. 

